Thomas robinson



7 NTOR was mw Fw' -)MLMM @ATTORNEYS Patented May 25, i926.

THOMAS ROBINSON, OF NEW YORK, N, Y.

RO OFING ELEMENT.

Application ilerl April 10, 1925. Serial No. 22,057'.

This invention relates to a new roofing product composed of variousmaterials of a water-resistant character which after suitable treatment,are formed into elements of different kinds appropriate for roofing andgeneral building purposes. More particularly, the present invention isintended to provide a new product which is cheap, d uiable, easily laid,and of considerable rigidity, and which is produced of ingredients whichare available at low prices and may be utilized in the manufacture ofthe new product with little labor.

Prepared ioolings of various kinds are now in wide use, and they affordnumerous yadvantages over wooden shingles, slate, tiles and the like.Such roofings are cheaper than the older materials, may be handled andlaid more conveniently, and, as compared with wooden shingles, theyreduce the fire hazard to a considerable extent. rlhese preparedproducts are sold commercially in various forms, such as in rolls, andas single and multiple-unit shingles, and in the types which have metwith the greatest commercial success, they include a base made of animpregnated roofing felt, or of asbestos board, or of wood fibreproducts. To the surface of the base, prepared by well-known methods, itis usual, in nearly all forms, to apply a coating of some weatherresistant product, over which is placed a coating of a good-wearingmaterial, such as crushed slate.

A typical example of such a prepared roofing consists of a felt made ofwool and rags, suitably compacted, and saturated with asphalt. Over oneor both surfaces of this felt base is applied a layer of asphalt of amelting` point such that it will withstand solar heat, and then over theupper surface is applied a coating of crushed slate, which is partiallyembedded in the coating layei` before the latter has completelyhardened.

Such products are satisfactory in many respects, although a roofingbuilt up of a felt base deteiiorates more or less rapidly upon exposureto the weather due to the rotting of the felt. This is particularlyundesirable when the rooting elements are in the form of shingles andlaid in courses, since the exposed edges warp or curl and `he roof takeson an unsightly appearance. Another objection lies in the fact thatthese products are neaily always made of a uniform thickness from oneend to the other and when laid in courses, the individual elements donot lie close together throughout their length but cavities occur at thebutt ends of the elements. Also these units are commonly inade with acomparatively thin base, which is lacking in rigidity. Another majorobjection is that the base products, such as felt, asbestos board, etc.,are quite expensive, even though cheaper than wood.

The object of the present invention is to provide a new roofing productwhich may be manufactured at a lower cost than the prepared roolings nowin use and in any of the shapes and forms desirable foi` building`purposes. More specifically, I intend to provide a product which, byreason of the manner in which it is made, may have varying degrees offlexibility and which possesses the strength and durability desired forproducts of this character. The new product is composed throughout ofmaterials which do not deteriorate upon exposure, and'may readily bemade in the tapered form, which is most suitable for roofing purposes.

While the new product may be made of various materials, I prefer toconstruct it of a jacket folded upon itself and enclosing a filler ofcomminuted inert material bound together by a plastic binder. In makinga tapered element the decrease in thickness toward the rear end wouldordinarily decrease the rigidity of the element, but the new element maybe made of uniform rigidity throughout its length, although thethickness is variable, by the use of comminuted inert materials gradedfor size, or of different specific gravities. The heavier material isused in that part of the filler which is in the thinner part of theelement, when materials of different specific gravities are employed,and when the saine material is used throughout the filler but; theparticles are of varying sizes, then the larger particles are arrangedso as to lie in the thinner part of the filler, while the smallerparticles lie in that part of the filler which occupies the thicker orbutt end of the element. The desired result is brought about by a propergrading or proportioniiig of the ingredients in the filler, and auniform rigidity throughout the element can readily be obtained in themanner presently to be described, even though the thickness of theelement may vary within wide limits from one end to the other.

For a better understandingof the invention, reference will now be `inadeto the accompanying drawings, in which Figs. 1 and 2 are face views ofmultiple unit and sin le unit shingles, respectively,

Fig. 3 is a face view of a modified form of single unit element,

Fig` l is a longitudina sectional view of one form of the new product,

Fig. 5 is a sectional view' on an enlarged scale of a portion of theelement shown in Fig. 4., and taken on the line 5-5 of that figure,

F ig. 6 is a sectional view showing a por tion of the end of the novelproduct at. one stage in the manufacture,

Fig. isa longitudinal sectional view ot a modified form of element, Y

Fig. 8 is a longitudinal sectional view of another modification, and

Fig. 9 is a face view of a completed three unit shingle.

Referring now to these drawings, there is shown in Fig. l, a three unitstrip shingle 11 provided with cut-out indentations 12, in its forwardedge. Similar cut-outs 13 of half width are formed at its side edges andwhen a series of these units is laid in a course, the cut-outs give theintervening areas 14 the appearance of spaced single shingles, the rearends of the cut-outs being concealed in the completed roof by the buttsof the shingles in the over-lapping course.

In Figs. 2 and 3 are shown single elements, the form shown in Fig. 2being made with cut-outs 15 along its side edges, while the unit shownin Fig. 3 is intended to be laid wit-h its edges 16 spaced from those ofthe next adjacent unit during the laying op eration.

The new product may be made in any of the forms shown and is preferablygiven a tapered cross-section Vfrom front to rear. It comprises, asshown in Figs. e and 5, a `iaclet sheet 17 which is substantially twiceas long as the length of the unit, this sheet being transversely foldedas at 1S. This sheet may be made of various materials, of which anasphalt-impregnated paper is typical. It is preferably, though notnecessarily, waterresistant and should have a fair degree of strength.It serves to confine the material of which the new product isprincipally made, during `the course of manufacture, and alsocontributes a certain amount of strength and durability to the finalproduct. It is not depended on, however, for its .vater-prooiingqualities, nor for itsy rigidity, and accordingly, various materialsother than asphalty paper will suggest themselves to those skilled inthe art as being useful for the purpose, although asphalt paper isnseaeea desirable because it is, among other things, of a low cost. Forexample, asbestos paper or acoarse grade of paper not impregnated, maybe used.

Having prepared a sheet of the proper dimensions andfo'lded it in themanner described, it is next supported in any approl priate way,preferably with its sides relieved from strain and spaced apartaccording tothe thickness of the element to be pro" duced. l/Vhen atapered element is to be made, the lsides of the sheet are supported indiverging relation. Into the fold of the sheet there Vis now introduced"the filler, which is made up of a comminuted inert inaterial, togetherwith a plastic vbinding com-- pound. 'I'his inert material may be ofvarious kinds, as, for example, crushed slate, crushed petroleum coke,infusorial earth, sand, gravel, pumice stone, with which may be mixedground cork or fibrous precincts such `as asbestos, peat, and the like.rllhe naturalproduct known as asphalt sand7 may also be used. Theplastic binding con pound is preferably a bituminous substance, such asasphalt.

In the utilization of these materials in the production of roofingelements, I find that a tapered element which is of superior quality,due to its Vsubstantially uniform rigidity, may be made by employing amixture of such inert materials for the filler, this mixture being madeup of materials which `are graded as to size, so that the density of thefiller may be controlled, or of t vo or more materials which havedifferent specic gravities. I have found that when the filler or body ofthe element is made of crushed slate, the particles of which vary from aline dust to 1/8 in size, for example, with asphalt as the plasticcoinpound, this yelement has a substantially uniform rigidity throughoutwhen the filling operation is carried on under such conditions t'hat thecoarser particles collect in the depth of the fold; that is, in thethinner part of the element; At the butt end of the element theparticles of slate are of much smaller size, but the element hassubstantially the same rigidity in this part as at the. thin end onaccount of the fact that lle although the particles of slate are liner,still before. In the thinner parts of the element the filler containsheavier particles of inert material, while on account of the greaterquant-ity of filler present in the butt end of the element, the use oflighter comminuted materials in the filler does not reduce the rigidityto any considerable extent, and, in fact, a substantially uniform.rigidity may be secured from one end of the element to the other by aproper selection of these materials, and by properly proportioning thequantities which are employed.

In introducing the filler into the fold of the sheet, the inert materialis first graded as to size, or when a mixture of two materials ofdifferent specific gravities are employed, the quantities are properlyproportioned so that the rigidity of` the final product may be thatdesired. Preferably, the inert materials used in the filler are mixedwith the plastic compound and continuously agitated. The plasticcompound is kept fluent by heat, and when a quantity of the filler isintroduced in the fold of the jacket, the desired proportion of coarseand line particles, or light and heavy particles, is included. l/Vhenslate and asphalt are employed, I have found it desirable to heat theslate to a temperature substantially that at which asphalt melts, and Ihave also found that since the melting point of the asphalt employedwill, to some extent, determine the rigidity of the Final product,because the stifl'cr the asphalt becomes on hardening, the higher themelting point it has, the asphalt will also be selected in accordancewith the type of product which is to be produced. The asphalt should, ofcourse, be selected in any event so as to withstand solar heat withoutsoftening. lVhen such a. plastic matrix is introduced into the fold ofthe jacket, the heaver particles tend to sink into the depth of thefold, while the lighter particles, some of which may be almost a dust,will remain suspended. This condition continues until the asphalt sets,andthe desired disposition of the particles of different sizes is thusbrought about.

lVhen materials of different spccilic gravities are employed,substantially the same lillug method is made use of. The matrix consistsof a quantity of a plastic composition, together with comminuted inertmaterials of dierent specific gravities, and in the desired proportions,which will depend on the rigidity which the final product is to have.rllhe stiffer the product to be made, the larger the proportion of theheavier inert material. Vhen this filler is introduced into the fold,

`the heavier inert material sinks into the bottom of the fold, thusoccupying the position which it is intended to take, while the lightermaterials remain more or less in suspension and occupy the butt end ofthe element. It is possible to introduce materials of different specificgravities into the fold in separate layers, if desired, pouring theplastic compound over them after they are in position. In some instancesthis method is preferable.

In the event that the comminuted material which is employed with theplastic substance to form the body, is lighter than the plasticsubstance, for instance, if the body is made of a mixture of asphalt andinfusorial earth or asbestos, then, owing to the difference in specificgravity between the comminuted material and the asphalt, the comminutedmaterial will, to a considerable extent, remain in suspension while theelement is being formed. Consequently, in the bottom of the fold of thesheet the body will consist almost entirely of asphalt, while thecomminuted material will lie in that part of the body remote from thefold. In this case the density of the body will vary from the line offolding outwardly, and, as before, the denser portions will lie nearerthe fold. However', in this case the desired rigidity is secured becausethe thinner parts of the body are occupied by heavier material, namely,the asphalt, and the parts of the body where the comminuted materialappears, and which are therefore, of less density, have an increasedthickness.

After the desired quantity of filler has been introduced into the jacketand allowed to become fairly hard, the element is removed from thesupport, and if cut-outs are to be formed, these are made by suitablecutting devices. Since the cutting operation is carried on before thefiller has completely set, the butt end may be easily molded to give theelement a splay edge as indicated at 20. Preferably the tapering of thebutt is continuous throughout the cut-out indentations. If desired, thebutt end of the element may be finished by causing the edges of thesheet to overlap so as to occupy the position illustrated in Fig. 7. Forthis purpose the liller is not introduced to the extreme edges of thefold, but parts 2l, and 22, of the sheet, as illustrated in Fig. 6, liebeyond the end of the filler. After the filler has been placed inposition, and preferably while it is still plastic, these extendingedges are turned inwardly, 011e upon the other, so that at the butt endthe filler is enclosed in a double thickness of the sheet.

After the cut-outs have been formed, or immediately after the filler hasset suiciently, if the element is to be without cut-outs, the clement iscoated throughout with a thin layer ,23 of a water-resistant compound,preferabl \Y of a plastic character which will harden on cooling.Various bituminous products such as asphalt are suitable for thepurpose. This coating layer seals the filler and makes the elementwater-proof, as well as helps to protect the reinforcing sheet fromwear. On top of the sealing coat, may be applied a thin layer Q4 ofcrushed llO Six

slate, crushed glass, etc., which provides `a wear surface and `enhancesthe appearance of the li ished product.

ln the element illustrated in Fig. 4.-, the con'nninuted fillingmaterial is shown as being of substantially the same size throughout thebody of filler, 4and in this element the ends ofthe jacket at lthe buttiend of the shingle are overlapped and the layer of crushed slate or thelike, `extends over the entire upper surface of the element ano aroundAthe butt end. The element shown in Fig. is a tapered element, fin whichcomminuted materials of two differentspecitio jravities are employed. lnthis elemeut, in which the `iiller lmay be considered to consist of amixture of crushed slate and ground cork, the slate is shown at asAoccupying the thin end of the element, while the larger particles ofcorlr are represented as at in the butt end of the element. ln 8 thereis shown an unfinished element in which a single kind of comminutedmaterial is employed, but having `particles of different sizes. ln thiselement the `inert material may be cruslied slate, for example, and theheavier particles occupy the `thin end of the shingle, as indicated at25', while the lighter particles which remain substantially susiiendedin the filler, occupy the space 1ndicated at 2G. 'it will be understoodthat the line of demarltation between the spaces occupied lby thedifferent kinds of material or the different sizes of the samemateria-l, is not as distinct as shown in the drawings, where two quitedistinct regions are in dicated merely for purposes `of greater clarityin illustration.

it will be seen that this new product `may be made of any desiredthickness, and that no difliculty is involved in producing taperedproducts. `ln its completed form all the edges Vwhere the filler isexposed, are protected by a sealing coating, which not only covers theside and end edges of the filler, but also the edgesV of the cut-outindentations so that there is no possibility of water entering betweenfiller andthe jacket, so as to cause a separation. Elements of varyingdegrees of rigidity or flexibility may be produced by the properselection of grades or kinds of comminuted material en'iployed, and theprocess vof manufacturing the product does not differ in producing`elements of varying characteristics, except in the selection of theproportions of different kinds of `inert materials which are used.

lt will be seen that the roofing product may be made at extremely lowcost since all the materials employed in its `construction are availableat low prices, and no considerable amount oflabor is employed. @ne ofthe principal items of expense of the prepared roolings now sold, andwhich include a felt base, is the felt, which is compara- Lacasseshingle of tapered configuration, and also fel-ft rooting shingles havea very considerable degree of flexibility, which, to some extent.reduces their popularity. lllhe present product, however, may bemanufactured in any shape and forn'nand may be given a taperedcross-section without additional ycost or difficulty. lt may vary withinwide limits .as Vto rigidity, and is suitable for `all buildingpurposes. l have found that it may be readily nailed in place, and maybe sewn with `ease, and `although it will ordi narily be made inelements which are comparatively stiff, still it is not brittle and ifsubjected to blows the iiiller will not crack `or break.

l claim:

l. A rooting element `comprising the combination of `a sheet doubledupon itself to provide a fold, and a body composed of a. luirdcnedplastic substance and coinminuted materials graded so that the densityof the body varies in `diffeuent parts there of, the rigidity beingsubstantially uniform.

2. A rooiiiig element comprising the com bination of a sheet doubledupon itself to provide va fold, and a body composed of a bituminousmatrix and an aggregate graded as to weight and so disposed that theheavier particles lie at the fold and Vthe particles gradually decreasein weight from the fold to the opposite end of the element.

3. Aroofing element comprising the coinbination of a sheet doubled uponitself `to provide a fold withthe plies of the sheet diverging from theline of folding, and a body composed of a bituminous matrix andcomminuted material lying in the fold, this body being so formed thatits density varies in different parts thereof, with the `denser portionslying nearer the fold, and the edges of the sheet remote from the foldbeing turned inwardly to overlie the 'end of the body.

4l. A roofing element comprising the combination of a sheet doubled uponitself to provide a fold and a body composed of a hardened plasticsubstance and comminuted material lying within the fold, this body beingso formed that its density varies in different parts thereof, with thedenser portions lying nearer the fold.

5. A tapered roofing element comprising the combinationof `a sheetdoubled upon itself to provide :a fold, the plies of the sheetldiverging from the line of folding7` -a body composed of a hardenedplastic substance and comminuted materials lying within the fold, thebody being so formed that its density varies indifferent parts thereof,with the denser portions lying nearer the fold, a

lll-fi sealing coat of asphalt applied to the outer face of the sheetand the exposed edges of the body, and a layer of crushed mineralmaterial embedded in the asphalt on one face of the sheet.

G. A roofing element comprising in conibination a sheet doubled nponitself lo pro-- vide a fold with the plies of the sheet diverging fromthe line of folding, and a body lying Within the sheet and comprising aquantity of particles o' ernshed slate of different sizes. the largerparticles occupying that part o t the body lying nearest the line offolding, and the size of the particles decreasing toward the oppositeend of the shingle.

7. A tapered shingle comprising in conibination, a sheet of asphaltpaper doubled upon itself to provide a fold, with the plies of the sheetdivcrging from the line of folding, a body lying Within the sheet andcomprising particles of crushed slate of different sizes, the largerparticles occupying that part of the body lying nearest the line offolding, and a sealing coat of asphalt capan ble of withstanding solai'heat, applied to the enter faces of the sheet and the exposed edges ofthe body.

8. A. tapered shingle comprising in combination, a sheet of asphaltpaper doubled upon itself to provide a fold, with the plies of the sheetdiverging from the line of folding, a body lying Within the sheet andcomprising a bituminous matrix and a mineral aggregate the body being soformed that its density varies in different parts thereof with thedenser portion lying nearer the fold, a plurality of cut-outindentations beingl formed in one edge of the sheet and body, and asealing coat of asphalt applied to the outer faces of the sheet and theexposed edges of the body including the sides of the indentations.

9. A tapered shingle comprising the co1n bination of a sheet of fibrousmaterial impregnated with a Waterproofing compound doubled upon itselfto provide a fold, a body of crushed slate and an asphaltic binder lyingwithin the fold, this body being of gra-dually increasing thickness fromthe fold and the plies of the sheet on either side of the fold coveringthe opposite faces of the body and extending beyond the latter, theextending portions being folded over the end of the body in overlappingrelation whereby the body is encased Within the sheet, and a sealingcoat of asphalt covering the outer faces of the sheetand the portions ofthe body exposed at either edge of the latter.

In testimony whereof I affix my signature.

THOMAS ROBINSON.

